|Publication number||US5914737 A|
|Application number||US 08/750,608|
|Publication date||Jun 22, 1999|
|Filing date||Apr 10, 1996|
|Priority date||Apr 12, 1995|
|Publication number||08750608, 750608, PCT/1996/4786, PCT/US/1996/004786, PCT/US/1996/04786, PCT/US/96/004786, PCT/US/96/04786, PCT/US1996/004786, PCT/US1996/04786, PCT/US1996004786, PCT/US199604786, PCT/US96/004786, PCT/US96/04786, PCT/US96004786, PCT/US9604786, US 5914737 A, US 5914737A, US-A-5914737, US5914737 A, US5914737A|
|Original Assignee||Eastman Kodak Company|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (48), Non-Patent Citations (6), Referenced by (116), Classifications (10), Legal Events (6)|
|External Links: USPTO, USPTO Assignment, Espacenet|
Reference is made to my commonly assigned, co-pending U.S. patent applications: Ser. No. 08/701,021 entitled CMOS PROCESS COMPATIBLE FABRICATION OF PRINT HEADS filed Aug. 21, 1996; Ser. No. 08/733,711 entitled CONSTRUCTION AND MANUFACTURING PROCESS FOR DROP ON DEMAND PRINT HEADS WITH NOZZLE HEATERS filed Oct. 17, 1996; Ser. No. 08/734,822 entitled A MODULAR PRINT HEAD ASSEMBLY filed Oct. 22, 1996; Ser. No. 08/736,537 entitled PRINT HEAD CONSTRUCTIONS FOR REDUCED ELECTROSTATIC INTERACTION BETWEEN PRINTED DROPLETS filed Oct. 24, 1996; Ser. No. 08/750,320 entitled NOZZLE DUPLICATION FOR FAULT TOLERANCE IN INTEGRATED PRINTING HEADS and Ser. No. 08/750,312 entitled HIGH CAPACITY COMPRESSED DOCUMENT IMAGE STORAGE FOR DIGITAL COLOR PRINTERS both filed Nov. 26, 1996; Ser. No. 08/753,718 entitled NOZZLE PLACEMENT IN MONOLITHIC DROP-ON-DEMAND PRINT HEADS and Ser. No. 08/750,606 entitled A COLOR VIDEO PRINTER AND A PHOTO CD SYSTEM WITH INTEGRATED PRINTER both filed on Nov. 27, 1996; Ser. No. 08/750,438 entitled A LIQUID INK PRINTING APPARATUS AND SYSTEM, Ser. No. 08/750,599 entitled COINCIDENT DROP SELECTION, DROP SEPARATION PRINTING METHOD AND SYSTEM, Ser. No. 08/750,435 entitled MONOLITHIC PRINT HEAD STRUCTURE AND A MANUFACTURING PROCESS THEREFOR USING ANISTROPIC WET ETCHING, Ser. No. 08/750,436 entitled POWER SUPPLY CONNECTION FOR MONOLITHIC PRINT HEADS, Ser. No. 08/750,437 entitled MODULAR DIGITAL PRINTING, Ser. No. 08/750,439 entitled A HIGH SPEED DIGITAL FABRIC PRINTER, Ser. No. 08/750,763 entitled A COLOR PHOTOCOPIER USING A DROP ON DEMAND INK JET PRINTING SYSTEM, Ser. No. 08/765,756 entitled PHOTOGRAPH PROCESSING AND COPYING SYSTEMS, Ser. No. 08/750,646 entitled FAX MACHINE WITH CONCURRENT DROP SELECTION AND DROP SEPARATION INK JET PRINTING, Ser. No. 08/759,774 entitled FAULT TOLERANCE IN HIGH VOLUME PRINTING PRESSES, Ser. No. 08/750,429 entitled INTEGRATED DRIVE CIRCUITRY IN DROP ON DEMAND PRINT HEADS, Ser. No. 08/750,433 entitled HEATER POWER COMPENSATION FOR TEMPERATURE IN THERMAL PRINTING SYSTEMS, Ser. No. 08/750,640 entitled HEATER POWER COMPENSATION FOR THERMAL LAG IN THERMAL PRINTING SYSTEMS, Ser. No. 08/750,650 entitled DATA DISTRIBUTION IN MONOLITHIC PRINT HEADS, and Ser. No. 08/750,642 entitled PRESSURIZABLE LIQUID INK CARTRIDGE FOR COINCIDENT FORCES PRINTERS all filed Dec. 3, 1996; Ser. No. 08/750,647 entitled MONOLITHIC PRINTING HEADS AND MANUFACTURING PROCESSES THEREFOR, Ser. No. 08/750,604 entitled INTEGRATED FOUR COLOR PRINT HEADS, Ser. No. 08/750,605 entitled A SELF-ALIGNED CONSTRUCTION AND MANUFACTURING PROCESS FOR MONOLITHIC PRINT HEADS, Ser. No. 08/682,603 entitled A COLOR PLOTTER USING CONCURRENT DROP SELECTION AND DROP SEPARATION INK JET PRINTING TECHNOLOGY, Ser. No. 08/750,603 entitled A NOTEBOOK COMPUTER WITH INTEGRATED CONCURRENT DROP SELECTION AND DROP SEPARATION COLOR PRINTING SYSTEM, Ser. No. 08/765,130 entitled INTEGRATED FAULT TOLERANCE IN PRINTING MECHANISMS; Ser. No. 08/750,431 entitled BLOCK FAULT TOLERANCE IN INTEGRATED PRINTING HEADS, Ser. No. 08/750,607 entitled FOUR LEVEL INK SET FOR BI-LEVEL COLOR PRINTING, Ser. No. 08/750,430 entitled A NOZZLE CLEARING PROCEDURE FOR LIQUID INK PRINTING, Ser. No. 08/750,600 entitled METHOD AND APPARATUS FOR ACCURATE CONTROL OF TEMPERATURE PULSES IN PRINTING HEADS, and Ser. No. 08/750,602 entitled IMPROVEMENTS IN IMAGE HALFTONING all filed Dec. 4, 1996; Ser. No. 08/765,127 entitled PRINTING METHOD AND APPARATUS EMPLOYING ELECTROSTATIC DROP SEPARATION, Ser. No. 08/750,643 entitled COLOR OFFICE PRINTER WITH A HIGH CAPACITY DIGITAL PAGE IMAGE STORE, and Ser. No. 08/765,035 entitled HEATER POWER COMPENSATION FOR PRINTING LOAD IN THERMAL PRINTING SYSTEMS all filed Dec. 5, 1996; Ser. No. 08/765,036 entitled APPARATUS FOR PRINTING MULTIPLE DROP SIZES AND FABRICATION THEREOF, Ser. No. 08/765,017 entitled HEATER STRUCTURE AND FABRICATION PROCESS FOR MONOLITHIC PRINT HEADS, Ser. No. 08/750,772 entitled DETECTION OF FAULTY ACTUATORS IN PRINTING HEADS, Ser. No. 08/765,037 entitled PAGE IMAGE AND FAULT TOLERANCE CONTROL APPARATUS FOR PRINTING SYSTEMS all filed Dec. 9, 1996; and Ser. No. 08/765,038 entitled CONSTRUCTIONS AND MANUFACTURING PROCESSES FOR THERMALLY ACTIVATED PRINT HEADS filed Dec. 10, 1996.
The present invention is in the field of computer controlled printing devices. In particular, the field is thermally activated drop on demand (DOD) printing systems.
The current invention is a small portable color printer for use with portable computers. Currently available portable printers are usually based on dot matrix pin printing techniques, thermal ink jet printing, or thermal transfer techniques. Most portable color printers are quite slow, requiring at least 60 seconds to print an A4 page. Portable printers are also usually of low to medium image quality, and very few types of portable full color printers exist.
A market need exists for portable printers able to print full color high quality images on plain paper or overhead transparency film. Ideally, such a printer should be low cost, light weight, high speed, and compatible with various page description languages in common use, such as Adobe's PostScript level 2, and Hewlett-Packard's PCL5.
Image quality comparable with quality color magazine publishing is also desirable.
Many different types of digitally controlled printing systems have been invented, and many types are currently in production. These printing systems use a variety of actuation mechanisms, a variety of marking materials, and a variety of recording media. Examples of digital printing systems in current use include: laser electrophotographic printers; LED electrophotographic printers; dot matrix impact printers; thermal paper printers; film recorders; thermal wax printers; dye diffusion thermal transfer printers; and ink jet printers. However, at present, such electronic printing systems have not significantly replaced mechanical printing presses, even though this conventional method requires very expensive setup and is seldom commercially viable unless a few thousand copies of a particular page are to be printed. Thus, there is a need for improved digitally controlled printing systems, for example, being able to produce high quality color images at a high-speed and low cost, using standard paper.
Inkjet printing has become recognized as a prominent contender in the digitally controlled, electronic printing arena because, e.g., of its non-impact, low-noise characteristics, its use of plain paper and its avoidance of toner transfers and fixing.
Many types of ink jet printing mechanisms have been invented. These can be categorized as either continuous ink jet (CIJ) or drop on demand (DOD) ink jet. Continuous inkjet printing dates back to at least 1929: Hansell, U.S. Pat. No. 1,941,001.
Sweet et al U.S. Pat. No. 3,373,437, 1967, discloses an array of continuous ink jet nozzles where ink drops to be printed are selectively charged and deflected towards the recording medium. This technique is known as binary deflection CIJ, and is used by several manufacturers, including Elmjet and Scitex.
Hertz et al U.S. Pat. No. 3,416,153, 1966, discloses a method of achieving variable optical density of printed spots in CIJ printing using the electrostatic dispersion of a charged drop stream to modulate the number of droplets which pass through a small aperture. This technique is used in ink jet printers manufactured by Iris Graphics.
Kyser et al U.S. Pat. No. 3,946,398, 1970, discloses a DOD ink jet printer which applies a high voltage to a piezoelectric crystal, causing the crystal to bend, applying pressure on an ink reservoir and jetting drops on demand. Many types of piezoelectric drop on demand printers have subsequently been invented, which utilize piezoelectric crystals in bend mode, push mode, shear mode, and squeeze mode. Piezoelectric DOD printers have achieved commercial success using hot melt inks (for example, Tektronix and Dataproducts printers), and at image resolutions up to 720 dpi for home and office printers (Seiko Epson). Piezoelectric DOD printers have an advantage in being able to use a wide range of inks. However, piezoelectric printing mechanisms usually require complex high voltage drive circuitry and bulky piezoelectric crystal arrays, which are disadvantageous in regard to manufacturability and performance.
Endo et al GB Pat. No. 2,007,162, 1979, discloses an electrothermal DOD ink jet printer which applies a power pulse to an electrothermal transducer (heater) which is in thermal contact with ink in a nozzle. The heater rapidly heats water based ink to a high temperature, whereupon a small quantity of ink rapidly evaporates, forming a bubble. The formation of these bubbles results in a pressure wave which cause drops of ink to be ejected from small apertures along the edge of the heater substrate. This technology is known as Bubblejet™ (trademark of Canon K.K. of Japan), and is used in a wide range of printing systems from Canon, Xerox, and other manufacturers.
Vaught et al U.S. Pat. No. 4,490,728, 1982, discloses an electrothermal drop ejection system which also operates by bubble formation. In this system, drops are ejected in a direction normal to the plane of the heater substrate, through nozzles formed in an aperture plate positioned above the heater. This system is known as Thermal Ink Jet, and is manufactured by Hewlett-Packard. In this document, the term Thermal Ink Jet is used to refer to both the Hewlett-Packard system and systems commonly known as Bubblejet™.
Thermal Ink Jet printing typically requires approximately 20 μJ over a period of approximately 2 μs to eject each drop. The 10 Watt active power consumption of each heater is disadvantageous in itself and also necessitates special inks, complicates the driver electronics and precipitates deterioration of heater elements.
Other ink jet printing systems have also been described in technical literature, but are not currently used on a commercial basis. For example, U.S. Pat. No. 4,275,290 discloses a system wherein the coincident address of predetermined print head nozzles with heat pulses and hydrostatic pressure, allows ink to flow freely to spacer-separated paper, passing beneath the print head. U.S. Pat. Nos. 4,737,803; and 4,748,458 disclose ink jet recording systems wherein the coincident address of ink in print head nozzles with heat pulses and an electrostatically attractive field cause ejection of ink drops to a print sheet.
Each of the above-described inkjet printing systems has advantages and disadvantages. However, there remains a widely recognized need for an improved ink jet printing approach, providing advantages for example, as to cost, speed, quality, reliability, power usage, simplicity of construction and operation, durability and consumables.
My concurrently filed applications, entitled "Liquid Ink Printing Apparatus and System" and "Coincident Drop-Selection, Drop-Separation Printing Method and System" describe new methods and apparatus that afford significant improvements toward overcoming the prior art problems discussed above. Those inventions offer important advantages, e.g., in regard to drop size and placement accuracy, as to printing speeds attainable, as to power usage, as to durability and operative thermal stresses encountered and as to other printer performance characteristics, as well as in regard to manufacturability and the characteristics of useful inks. One important purpose of the present invention is to further enhance the structures and methods described in those applications and thereby contribute to the advancement of printing technology.
The invention provides a portable color printer using a printing head operating on the concurrent drop selection and drop separation ink jet printing principle.
A preferred form of the invention provides a color printing apparatus comprising:
1) a connection to a computer;
2) a PDL interpreter;
3) a digital halftoning unit which converts the continuous tone image data output by the PDL interpreter to bi-level image data;
4) a bi-level page memory used to store at least one full page of bi-level data;
5) a data distribution and timing system which provides the bi-level image data to the printing head at the correct time during a printing operation; and
6) a bi-level printing mechanism operating on the concurrent drop selection and drop separation printing principle.
Another preferred form of the invention provides a color printing apparatus comprising:
1) a connection to a computer;
2) a data distribution and timing system which provides bi-level image data to the printing head at the correct time during a printing operation; and
3) a page width bi-level printing mechanism which ejects drops of liquid ink when activated by an electrical pulse,
4) wherein the bi-level image data is calculated by the computer, and provided to the data distribution and timing system substantially synchronously with the paper movement past the printing head.
FIG. 1 (a) shows a simplified block schematic diagram of one exemplary printing apparatus according to the present invention.
FIG. 1 (b) shows a cross section of one variety of nozzle tip in accordance with the invention.
FIGS. 2(a) to 2(f) show fluid dynamic simulations of drop selection.
FIG. 3(a) shows a finite element fluid dynamic simulation of a nozzle in operation according to an embodiment of the invention.
FIG. 3(b) shows successive meniscus positions during drop selection and separation.
FIG. 3(c) shows the temperatures at various points during a drop selection cycle.
FIG. 3(d) shows measured surface tension versus temperature curves for various ink additives.
FIG. 3(e) shows the power pulses which are applied to the nozzle heater to generate the temperature curves of FIG. 3(c)
FIG. 4 shows a block schematic diagram of print head drive circuitry for practice of the invention.
FIG. 5 shows projected manufacturing yields for an A4 page width color print head embodying features of the invention, with and without fault tolerance.
FIG. 6 shows a simplified schematic diagram of a portable printer using printing technology.
FIG. 7(a) shows a top view of major component placement in one configuration of the printer.
FIG. 7(b) shows a side view of major component placement in one configuration of the printer.
FIG. 8 shows a perspective view of one possible configuration of the printer.
FIG. 9 shows a simplified schematic diagram of a miniature portable color printer.
FIG. 10(a) shows a side view of major component placement in one configuration of the printer.
FIG. 10(b) shows a front view of major component placement in one configuration of the printer.
FIG. 10(c) shows a top view of major component placement in one configuration of the printer.
The invention is a portable, high quality color printer for use with notebook or other portable computers or in an office environment. The system uses a concurrent drop selection and drop separation drop on demand printing mechanism.
The printer interprets information supplied by an external computer in the form one of more page description languages (PDLs) to create a continuous tone page image. This image is converted to a bi-level image by digital halftoning, and stored in a bi-level page memory. The contents of the page memory can then be printed using a printing head according to the present invention.
A notebook computer calculates the image in a bitmap form, and provides this bitmap to the printer. The bitmap image is typically calculated using an imaging model provided by the notebook operating system, for example QuickDraw or QuickDraw GX on Apple Macintosh computers, and Microsoft GDI on computers running the Microsoft Windows operating system. This image is stored in the internal memory of the notebook computer, and is provided to the printer substantially synchronously to the movement of the print head relative to the paper. The bitmap data controls the ejection of ink drops from the printing head, thus forming an image on the paper.
In one general aspect, the invention constitutes a drop-on-demand printing mechanism wherein the means of selecting drops to be printed produces a difference in position between selected drops and drops which are not selected, but which is insufficient to cause the ink drops to overcome the ink surface tension and separate from the body of ink, and wherein an alternative means is provided to cause separation of the selected drops from the body of ink.
The separation of drop selection means from drop separation means significantly reduces the energy required to select which ink drops are to be printed. Only the drop selection means must be driven by individual signals to each nozzle.
The drop separation means can be a field or condition applied simultaneously to all nozzles.
The drop selection means may be chosen from, but is not limited to, the following list:
1) Electrothermal reduction of surface tension of pressurized ink
2) Electrothermal bubble generation, with insufficient bubble volume to cause drop ejection
3) Piezoelectric, with insufficient volume change to cause drop ejection
4) Electrostatic attraction with one electrode per nozzle
The drop separation means may be chosen from, but is not limited to, the following list:
1) Proximity (recording medium in close proximity to print head)
2) Proximity with oscillating ink pressure
3) Electrostatic attraction
4) Magnetic attraction
The table "DOD printing technology targets" shows some desirable characteristics of drop on demand printing technology. The table also lists some methods by which some embodiments described herein, or in other of my related applications, provide improvements over the prior art.
______________________________________DOD printing technology targetsTarget Method of achieving improvement over prior art______________________________________High speed Practical, low cost, pagewidth printing heads with moreoperation than 10,000 nozzles. Monolithic A4 pagewidth print heads can be manufactured using standard 300 mm (12") silicon wafersHigh image High resolution (800 dpi is sufficient for mostquality applications), six color process to reduce image noiseFull color Halftoned process color at 800 dpi using stochasticoperation screeningInk flexibility Low operating ink temperature and no requirement for bubble formationLow power Low power operation results from drop selection meansrequirements not being required to fully eject dropLow cost Monolithic print head without aperture plate, high manufacturing yield, small number of electrical connections, use of modified existing CMOS manufacturing facilitiesHigh Manufac- Integrated fault tolerance in printing headturing yieldHigh reliability Integrated fault tolerance in printing head. Elimination of cavitation and kogation. Reduction of thermal shock.Small number Shift registers, control logic, and drive circuitry can beof electrical integrated on a monolithic print head using standardconnections CMOS processesUse of existing CMOS compatibility. This can be achieved because theVLSI manufac- heater drive power is less is than 1% of Thermal Ink Jetturing heater drive powerfacilitiesElectronic A new page compression system which can achievecollation 100:1 compression with insignificant image degradation, resulting in a compressed data rate low enough to allow real-time printing of any combination of thousands of pages stored on a low cost magnetic disk drive.______________________________________
In thermal ink jet (TIJ) and piezoelectric ink jet systems, a drop velocity of approximately 10 meters per second is preferred to ensure that the selected ink drops overcome ink surface tension, separate from the body of the ink, and strike the recording medium. These systems have a very low efficiency of conversion of electrical energy into drop kinetic energy. The efficiency of TIJ systems is approximately 0.02%). This means that the drive circuits for TIJ print heads must switch high currents. The drive circuits for piezoelectric ink jet heads must either switch high voltages, or drive highly capacitive loads. The total power consumption of pagewidth TIJ printheads is also very high. An 800 dpi A4 full color pagewidth TIJ print head printing a four color black image in one second would consume approximately 6 kW of electrical power, most of which is converted to waste heat. The difficulties of removal of this amount of heat precludes the production of low cost, high speed, high resolution compact pagewidth TIJ systems.
One important feature of embodiments of the invention is a means of significantly reducing the energy required to select which ink drops are to be printed. This is achieved by separating the means for selecting ink drops from the means for ensuring that selected drops separate from the body of ink and form dots on the recording medium. Only the drop selection means must be driven by individual signals to each nozzle. The drop separation means can be a field or condition applied simultaneously to all nozzles.
The table "Drop selection means" shows some of the possible means for selecting drops in accordance with the invention. The drop selection means is only required to create sufficient change in the position of selected drops that the drop separation means can discriminate between selected and unselected drops.
______________________________________Drop selection meansMethod Advantage Limitation______________________________________1. Electrothermal Low temperature Requires ink pressurereduction of increase and low drop regulating mechanism. Inksurface tension of selection energy. Can be surface tension must reducepressurized ink used with many ink substantially as temperature types. Simple fabrication. increases CMOS drive circuits can be fabricated on same substrate2. Electrothermal Medium drop selection Requires ink pressurereduction of ink energy, suitable for hot oscillation mechanism. Inkviscosity, melt and oil based inks. must have a large decreasecombined with Simple fabrication. in viscosity as temperatureoscillating CMOS drive circuits can increasesink pressure be fabricated on same substrate3. Electrothermal Well known technology, High drop selection energy,bubble genera- simple fabrication, requires water based ink,tion, with bipolar drive circuits can problems with kogation,insufficient be fabricated on same cavitation, thermal stressbubble volume to substratecause dropejection4. Piezoelectric, Many types of ink base High manufacturing cost,with insufficient can be used incompatible withvolume change to integrated circuit processes,cause drop high drive voltage,ejection mechanical complexity, bulky5. Electrostatic Simple electrode Nozzle pitch must beattraction with fabrication relatively large. Crosstalkone electrode per between adjacent electricnozzle fields. Requires high voltage drive circuits______________________________________
Other drop selection means may also be used.
The preferred drop selection means for water based inks is method 1: "Electrothermal reduction of surface tension of pressurized ink". This drop selection means provides many advantages over other systems, including; low power operation (approximately 1% of TIJ), compatibility with CMOS VLSI chip fabrication, low voltage operation (approx. 10 V), high nozzle density, low temperature operation, and wide range of suitable ink formulations. The ink must exhibit a reduction in surface tension with increasing temperature.
The preferred drop selection means for hot melt or oil based inks is method 2: "electrothermal reduction of ink viscosity, combined with oscillating ink pressure". This drop selection means is particularly suited for use with inks which exhibit a large reduction of viscosity with increasing temperature, but only a small reduction in surface tension. This occurs particularly with non-polar ink carriers with relatively high molecular weight. This is especially applicable to hot melt and oil based inks.
The table "Drop separation means" shows some of the possible methods for separating selected drops from the body of ink, and ensuring that the selected drops form dots on the printing medium. The drop separation means discriminates between selected drops and unselected drops to ensure that unselected drops do not form dots on the printing medium.
______________________________________Drop separation meansMeans Advantage Limitation______________________________________1. Electrostatic Can print on rough Requires high voltageattraction surfaces, simple power supply implementation2. AC electric Higher field strength is Requires high voltage ACfield possible than electrostatic, power supply synchronized operating margins can be to drop ejection phase. increased, ink pressure Multiple drop phase reduced, and dust operation is difficult accumulation is reduced3. Proximity Very small spot sizes can Requires print medium to(print head in be achieved. Very low be very close to print headclose proximity power dissipation. High surface, not suitable forto, but not drop position accuracy rough print media, usuallytouching, requires transfer roller orrecording beltmedium)4. Transfer Very small spot sizes can Not compact due to size ofProximity be achieved, very low transfer roller or transfer(print head is in power dissipation, high belt.close proximity accuracy, can print onto a transfer rough paperroller or belt5. Proximity Useful for hot melt inks Requires print medium towith oscillating using viscosity reduction be very close to print headink pressure drop selection method, surface, not suitable for reduces possibility of rough print media. Requires nozzle clogging, can use ink pressure oscillation pigments instead of dyes apparatus6. Magnetic Can print on rough Requires uniform highattraction surfaces. Low power if magnetic field strength, permanent magnets are requires magnetic ink used______________________________________
Other drop separation means may also be used.
The preferred drop separation means depends upon the intended use. For most applications, method 1: "Electrostatic attraction", or method 2: "AC electric field" are most appropriate. For applications where smooth coated paper or film is used, and very high speed is not essential, method 3: "Proximity" may be appropriate. For high speed, high quality systems, method 4: "Transfer proximity" can be used. Method 6: "Magnetic attraction" is appropriate for portable printing systems where the print medium is too rough for proximity printing, and the high voltages required for electrostatic drop separation are undesirable. There is no clear `best` drop separation means which is applicable to all circumstances.
A simplified schematic diagram of one preferred printing system according to the invention appears in FIG. 1(a).
An image source 52 may be raster image data from a scanner or computer, or outline image data in the form of a page description language (PDL), or other forms of digital image representation. This image data is converted to a pixel-mapped page image by the image processing system 53. This may be a raster image processor (RIP) in the case of PDL image data, or may be pixel image manipulation in the case of raster image data. Continuous tone data produced by the image processing unit 53 is halftoned. Halftoning is performed by the Digital Halftoning unit 54. Halftoned bitmap image data is stored in the image memory 72. Depending upon the printer and system configuration, the image memory 72 may be a full page memory, or a band memory. Heater control circuits 71 read data from the image memory 72 and apply time-varying electrical pulses to the nozzle heaters (103 in FIG. 1(b)) that are part of the print head 50. These pulses are applied at an appropriate time, and to the appropriate nozzle, so that selected drops will form spots on the recording medium 51 in the appropriate position designated by the data in the image memory 72.
The recording medium 51 is moved relative to the head 50 by a paper transport system 65, which is electronically controlled by a paper transport control system 66, which in turn is controlled by a microcontroller 315. The paper transport system shown in FIG. 1(a) is schematic only, and many different mechanical configurations are possible. In the case of pagewidth print heads, it is most convenient to move the recording medium 51 past a stationary head 50. However, in the case of scanning print systems, it is usually most convenient to move the head 50 along one axis (the sub-scanning direction) and the recording medium 51 along the orthogonal axis (the main scanning direction), in a relative raster motion. The microcontroller 315 may also control the ink pressure regulator 63 and the heater control circuits 71.
For printing using surface tension reduction, ink is contained in an ink reservoir 64 under pressure. In the quiescent state (with no ink drop ejected), the ink pressure is insufficient to overcome the ink surface tension and eject a drop. A constant ink pressure can be achieved by applying pressure to the ink reservoir 64 under the control of an ink pressure regulator 63. Alternatively, for larger printing systems, the ink pressure can be very accurately generated and controlled by situating the top surface of the ink in the reservoir 64 an appropriate distance above the head 50. This ink level can be regulated by a simple float valve (not shown).
For printing using viscosity reduction, ink is contained in an ink reservoir 64 under pressure, and the ink pressure is caused to oscillate. The means of producing this oscillation may be a piezoelectric actuator mounted in the ink channels (not shown).
When properly arranged with the drop separation means, selected drops proceed to form spots on the recording medium 51, while unselected drops remain part of the body of ink.
The ink is distributed to the back surface of the head 50 by an ink channel device 75. The ink preferably flows through slots and/or holes etched through the silicon substrate of the head 50 to the front surface, where the nozzles and actuators are situated. In the case of thermal selection, the nozzle actuators are electrothermal heaters.
In some types of printers according to the invention, an external field 74 is required to ensure that the selected drop separates from the body of the ink and moves towards the recording medium 51. A convenient external field 74 is a constant electric field, as the ink is easily made to be electrically conductive. In this case, the paper guide or platen 67 can be made of electrically conductive material and used as one electrode generating the electric field. The other electrode can be the head 50 itself. Another embodiment uses proximity of the print medium as a means of discriminating between selected drops and unselected drops.
For small drop sizes gravitational force on the ink drop is very small; approximately 10-4 of the surface tension forces, so gravity can be ignored in most cases. This allows the print head 50 and recording medium 51 to be oriented in any direction in relation to the local gravitational field. This is an important requirement for portable printers.
FIG. 1(b) is a detail enlargement of a cross section of a single microscopic nozzle tip embodiment of the invention, fabricated using a modified CMOS process. The nozzle is etched in a substrate 101, which may be silicon, glass, metal, or any other suitable material. If substrates which are not semiconductor materials are used, a semiconducting material (such as amorphous silicon) may be deposited on the substrate, and integrated drive transistors and data distribution circuitry may be formed in the surface semiconducting layer. Single crystal silicon (SCS) substrates have several advantages, including:
1) High performance drive transistors and other circuitry can be fabricated in SCS;
2) Print heads can be fabricated in existing facilities (fabs) using standard VLSI processing equipment;
3) SCS has high mechanical strength and rigidity; and
4) SCS has a high thermal conductivity.
In this example, the nozzle is of cylindrical form, with the heater 103 forming an annulus. The nozzle tip 104 is formed from silicon dioxide layers 102 deposited during the fabrication of the CMOS drive circuitry. The nozzle tip is passivated with silicon nitride. The protruding nozzle tip controls the contact point of the pressurized ink 100 on the print head surface. The print head surface is also hydrophobized to prevent accidental spread of ink across the front of the print head.
Many other configurations of nozzles are possible, and nozzle embodiments of the invention may vary in shape, dimensions, and materials used. Monolithic nozzles etched from the substrate upon which the heater and drive electronics are formed have the advantage of not requiring an orifice plate. The elimination of the orifice plate has significant cost savings in manufacture and assembly. Recent methods for eliminating orifice plates include the use of `vortex` actuators such as those described in Domoto et al U.S. Pat. No. 4,580,158, 1986, assigned to Xerox, and Miller et al U.S. Pat. No. 5,371,527, 1994 assigned to Hewlett-Packard. These, however are complex to actuate, and difficult to fabricate. The preferred method for elimination of orifice plates for print heads of the invention is incorporation of the orifice into the actuator substrate.
This type of nozzle may be used for print heads using various techniques for drop separation.
Operation with Electrostatic Drop Separation
As a first example, operation using thermal reduction of surface tension and electrostatic drop separation is shown in FIG. 2.
FIG. 2 shows the results of energy transport and fluid dynamic simulations performed using FIDAP, a commercial fluid dynamic simulation software package available from Fluid Dynamics Inc., of Illinois, USA. This simulation is of a thermal drop selection nozzle embodiment with a diameter of 8 μm, at an ambient temperature of 30° C. The total energy applied to the heater is 276 nJ, applied as 69 pulses of 4 nJ each. The ink pressure is 10 kPa above ambient air pressure, and the ink viscosity at 30° C. is 1.84 cPs. The ink is water based, and includes a sol of 0.1% palmitic acid to achieve an enhanced decrease in surface tension with increasing temperature. A cross section of the nozzle tip from the central axis of the nozzle to a radial distance of 40 μm is shown. Heat flow in the various materials of the nozzle, including silicon, silicon nitride, amorphous silicon dioxide, crystalline silicon dioxide, and water based ink are simulated using the respective densities, heat capacities, and thermal conductivities of the materials. The time step of the simulation is 0.1 μs.
FIG. 2(a) shows a quiescent state, just before the heater is actuated. An equilibrium is created whereby no ink escapes the nozzle in the quiescent state by ensuring that the ink pressure plus external electrostatic field is insufficient to overcome the surface tension of the ink at the ambient temperature. In the quiescent state, the meniscus of the ink does not protrude significantly from the print head surface, so the electrostatic field is not significantly concentrated at the meniscus.
FIG. 2(b) shows thermal contours at 5° C. intervals 5 μs after the start of the heater energizing pulse. When the heater is energized, the ink in contact with the nozzle tip is rapidly heated. The reduction in surface tension causes the heated portion of the meniscus to rapidly expand relative to the cool ink meniscus. This drives a convective flow which rapidly transports this heat over part of the free surface of the ink at the nozzle tip. It is necessary for the heat to be distributed over the ink surface, and not just where the ink is in contact with the heater. This is because viscous drag against the solid heater prevents the ink directly in contact with the heater from moving.
FIG. 2(c) shows thermal contours at 5° C. intervals 10 μs after the start of the heater energizing pulse. The increase in temperature causes a decrease in surface tension, disturbing the equilibrium of forces. As the entire meniscus has been heated, the ink begins to flow.
FIG. 2(d) shows thermal contours at 5° C. intervals 20 μs after the start of the heater energizing pulse. The ink pressure has caused the ink to flow to a new meniscus position, which protrudes from the print head. The electrostatic field becomes concentrated by the protruding conductive ink drop.
FIG. 2(e) shows thermal contours at 5° C. intervals 30 μs after the start of the heater energizing pulse, which is also 6 μs after the end of the heater pulse, as the heater pulse duration is 24 μs. The nozzle tip has rapidly cooled due to conduction through the oxide layers, and conduction into the flowing ink. The nozzle tip is effectively `water cooled` by the ink. Electrostatic attraction causes the ink drop to begin to accelerate towards the recording medium. Were the heater pulse significantly shorter (less than 16 μs in this case) the ink would not accelerate towards the print medium, but would instead return to the nozzle.
FIG. 2(f) shows thermal contours at 5° C. intervals 26 μs after the end of the heater pulse. The temperature at the nozzle tip is now less than 5° C. above ambient temperature. This causes an increase in surface tension around the nozzle tip. When the rate at which the ink is drawn from the nozzle exceeds the viscously limited rate of ink flow through the nozzle, the ink in the region of the nozzle tip `necks`, and the selected drop separates from the body of ink. The selected drop then travels to the recording medium under the influence of the external electrostatic field. The meniscus of the ink at the nozzle tip then returns to its quiescent position, ready for the next heat pulse to select the next ink drop. One ink drop is selected, separated and forms a spot on the recording medium for each heat pulse. As the heat pulses are electrically controlled, drop on demand ink jet operation can be achieved.
FIG. 3(a) shows successive meniscus positions during the drop selection cycle at 5 μs intervals, starting at the beginning of the heater energizing pulse.
FIG. 3(b) is a graph of meniscus position versus time, showing the movement of the point at the centre of the meniscus. The heater pulse starts 10 μs into the simulation.
FIG. 3(c) shows the resultant curve of temperature with respect to time at various points in the nozzle. The vertical axis of the graph is temperature, in units of 100° C. The horizontal axis of the graph is time, in units of 10 μs. The temperature curve shown in FIG. 3(b) was calculated by FIDAP, using 0.1 μs time steps. The local ambient temperature is 30 degrees C. Temperature histories at three points are shown:
A--Nozzle tip: This shows the temperature history at the circle of contact between the passivation layer, the ink, and air.
B--Meniscus midpoint: This is at a circle on the ink meniscus midway between the nozzle tip and the centre of the meniscus.
C--Chip surface: This is at a point on the print head surface 20 μm from the centre of the nozzle. The temperature only rises a few degrees. This indicates that active circuitry can be located very close to the nozzles without experiencing performance or lifetime degradation due to elevated temperatures.
FIG. 3(e) shows the power applied to the heater. Optimum operation requires a sharp rise in temperature at the start of the heater pulse, a maintenance of the temperature a little below the boiling point of the ink for the duration of the pulse, and a rapid fall in temperature at the end of the pulse. To achieve this, the average energy applied to the heater is varied over the duration of the pulse. In this case, the variation is achieved by pulse frequency modulation of 0.1 μs sub-pulses, each with an energy of 4 nJ. The peak power applied to the heater is 40 mW, and the average power over the duration of the heater pulse is 11.5 mW. The sub-pulse frequency in this case is 5 Mhz. This can readily be varied without significantly affecting the operation of the print head. A higher sub-pulse frequency allows finer control over the power applied to the heater. A sub-pulse frequency of 13.5 Mhz is suitable, as this frequency is also suitable for minimizing the effect of radio frequency interference (RFI).
Inks with a negative temperature coefficient of surface tension
The requirement for the surface tension of the ink to decrease with increasing temperature is not a major restriction, as most pure liquids and many mixtures have this property. Exact equations relating surface tension to temperature for arbitrary liquids are not available. However, the following empirical equation derived by Ramsay and Shields is satisfactory for many liquids: ##EQU1##
Where γT is the surface tension at temperature T, k is a constant, Tc is the critical temperature of the liquid, M is the molar mass of the liquid, x is the degree of association of the liquid, and ρ is the density of the liquid. This equation indicates that the surface tension of most liquids falls to zero as the temperature reaches the critical temperature of the liquid. For most liquids, the critical temperature is substantially above the boiling point at atmospheric pressure, so to achieve an ink with a large change in surface tension with a small change in temperature around a practical ejection temperature, the admixture of surfactants is recommended.
The choice of surfactant is important. For example, water based ink for thermal ink jet printers often contains isopropyl alcohol (2-propanol) to reduce the surface tension and promote rapid drying. Isopropyl alcohol has a boiling point of 82.4° C., lower than that of water. As the temperature rises, the alcohol evaporates faster than the water, decreasing the alcohol concentration and causing an increase in surface tension. A surfactant such as 1-Hexanol (b.p. 158° C.) can be used to reverse this effect, and achieve a surface tension which decreases slightly with temperature. However, a relatively large decrease in surface tension with temperature is desirable to maximize operating latitude. A surface tension decrease of 20 mN/m over a 30° C. temperature range is preferred to achieve large operating margins, while as little as 10 mN/m can be used to achieve operation of the print head according to the present invention.
Inks With Large-ΔγT
Several methods may be used to achieve a large negative change in surface tension with increasing temperature. Two such methods are:
1) The ink may contain a low concentration sol of a surfactant which is solid at ambient temperatures, but melts at a threshold temperature. Particle sizes less than 1,000 Å are desirable. Suitable surfactant melting points for a water based ink are between 50° C. and 90° C., and preferably between 60° C. and 80° C.
2) The ink may contain an oil/water microemulsion with a phase inversion temperature (PIT) which is above the maximum ambient temperature, but below the boiling point of the ink. For stability, the PIT of the microemulsion is preferably 20° C. or more above the maximum non-operating temperature encountered by the ink. A PIT of approximately 80° C. is suitable.
Inks with Surfactant Sols
Inks can be prepared as a sol of small particles of a surfactant which melts in the desired operating temperature range. Examples of such surfactants include carboxylic acids with between 14 and 30 carbon atoms, such as:
______________________________________Name Formula m.p. Synonym______________________________________Tetradecanoic acid CH3 (CH2)12 COOH 58° C. Myristic acidHexadecanoic acid CH3 (CH2)14 COOH 63° C. Palmitic acidOctadecanoic acid CH3 (CH2)15 COOH 71° C. Stearic acidEicosanoic acid CH3 (CH2)16 COOH 77° C. Arachidic acidDocosanoic acid CH3 (CH2)20 COOH 80° C. Behenic acid______________________________________
As the melting point of sols with a small particle size is usually slightly less than of the bulk material, it is preferable to choose a carboxylic acid with a melting point slightly above the desired drop selection temperature. A good example is Arachidic acid.
These carboxylic acids are available in high purity and at low cost. The amount of surfactant required is very small, so the cost of adding them to the ink is insignificant. A mixture of carboxylic acids with slightly varying chain lengths can be used to spread the melting points over a range of temperatures. Such mixtures will typically cost less than the pure acid.
It is not necessary to restrict the choice of surfactant to simple unbranched carboxylic acids. Surfactants with branched chains or phenyl groups, or other hydrophobic moieties can be used. It is also not necessary to use a carboxylic acid. Many highly polar moieties are suitable for the hydrophilic end of the surfactant. It is desirable that the polar end be ionizable in water, so that the surface of the surfactant particles can be charged to aid dispersion and prevent flocculation. In the case of carboxylic acids, this can be achieved by adding an alkali such as sodium hydroxide or potassium hydroxide.
Preparation of Inks with Surfactant Sols
The surfactant sol can be prepared separately at high concentration, and added to the ink in the required concentration.
An example process for creating the surfactant sol is as follows:
1) Add the carboxylic acid to purified water in an oxygen free atmosphere.
2) Heat the mixture to above the melting point of the carboxylic acid. The water can be brought to a boil.
3) Ultrasonicate the mixture, until the typical size of the carboxylic acid droplets is between 100 Å and 1,000 Å.
4) Allow the mixture to cool.
5) Decant the larger particles from the top of the mixture.
6) Add an alkali such as NaOH to ionize the carboxylic acid molecules on the surface of the particles. A pH of approximately 8 is suitable. This step is not absolutely necessary, but helps stabilize the sol.
7) Centrifuge the sol. As the density of the carboxylic acid is lower than water, smaller particles will accumulate at the outside of the centrifuge, and larger particles in the centre.
8) Filter the sol using a microporous filter to eliminate any particles above 5000 Å.
9) Add the surfactant sol to the ink preparation. The sol is required only in very dilute concentration.
The ink preparation will also contain either dye(s) or pigment(s), bactericidal agents, agents to enhance the electrical conductivity of the ink if electrostatic drop separation is used, humectants, and other agents as required.
Anti-foaming agents will generally not be required, as there is no bubble formation during the drop ejection process.
Cationic surfactant sols
Inks made with anionic surfactant sols are generally unsuitable for use with cationic dyes or pigments. This is because the cationic dye or pigment may precipitate or flocculate with the anionic surfactant. To allow the use of cationic dyes and pigments, a cationic surfactant sol is required. The family of alkylamines is suitable for this purpose.
Various suitable alkylamines are shown in the following table:
______________________________________Name Formula Synonym______________________________________Hexadecylamine CH3 (CH2)14 CH2 NH2 Palmityl amineOctadecylamine CH3 (CH2)16 CH2 NH2 Stearyl amineEicosylamine CH3 (CH2)18 CH2 NH2 Arachidyl amineDocosylamine CH3 (CH2)20 CH2 NH2 Behenyl amine______________________________________
The method of preparation of cationic surfactant sols is essentially similar to that of anionic surfactant sols, except that an acid instead of an alkali is used to adjust the pH balance and increase the charge on the surfactant particles. A pH of 6 using HCl is suitable.
Microemulsion Based Inks
An alternative means of achieving a large reduction in surface tension as some temperature threshold is to base the ink on a microemulsion. A microemulsion is chosen with a phase inversion temperature (PIT) around the desired ejection threshold temperature. Below the PIT, the microemulsion is oil in water (O/W), and above the PIT the microemulsion is water in oil (W/O). At low temperatures, the surfactant forming the microemulsion prefers a high curvature surface around oil, and at temperatures significantly above the PIT, the surfactant prefers a high curvature surface around water. At temperatures close to the PIT, the microemulsion forms a continuous `sponge` of topologically connected water and oil.
There are two mechanisms whereby this reduces the surface tension. Around the PIT, the surfactant prefers surfaces with very low curvature. As a result, surfactant molecules migrate to the ink/air interface, which has a curvature which is much less than the curvature of the oil emulsion. This lowers the surface tension of the water. Above the phase inversion temperature, the microemulsion changes from O/W to W/O, and therefore the ink/air interface changes from water/air to oil/air. The oil/air interface has a lower surface tension.
There is a wide range of possibilities for the preparation of microemulsion based inks.
For fast drop ejection, it is preferable to chose a low viscosity oil.
In many instances, water is a suitable polar solvent. However, in some cases different polar solvents may be required. In these cases, polar solvents with a high surface tension should be chosen, so that a large decrease in surface tension is achievable.
The surfactant can be chosen to result in a phase inversion temperature in the desired range. For example, surfactants of the group poly(oxyethylene)alkylphenyl ether (ethoxylated alkyl phenols, general formula: Cn H2n+1 C4 H6 (CH2 CH2 O)m OH) can be used. The hydrophilicity of the surfactant can be increased by increasing m, and the hydrophobicity can be increased by increasing n. Values of m of approximately 10, and n of approximately 8 are suitable.
Low cost commercial preparations are the result of a polymerization of various molar ratios of ethylene oxide and alkyl phenols, and the exact number of oxyethylene groups varies around the chosen mean. These commercial preparations are adequate, and highly pure surfactants with a specific number of oxyethylene groups are not required.
The formula for this surfactant is C8 H17 C4 H(CH2 CH2 O)n OH (average n=10).
Synonyms include Octoxynol-10, PEG-10 octyl phenyl ether and POE (10) octyl phenyl ether
The HLB is 13.6, the melting point is 7° C., and the cloud point is 65° C.
Commercial preparations of this surfactant are available under various brand names. Suppliers and brand names are listed in the following table:
______________________________________Trade name Supplier______________________________________Akyporox OP100 Chem-Y GmbHAlkasurf OP-10 Rhone-Poulenc Surfactants and SpecialtiesDehydrophen POP 10 Pulcra SAHyonic OP-10 Henkel Corp.Iconol OP-10 BASF Corp.Igepal O Rhone-Poulenc FranceMacol OP-10 PPG IndustriesMalorphen 810 Huls AGNikkol OP-10 Nikko Chem. Co. Ltd.Renex 750 ICI Americas Inc.Rexol 45/10 Hart Chemical Ltd.Synperonic OP10 ICI PLCTeric X10 ICI Australia______________________________________
These are available in large volumes at low cost (less than one dollar per pound in quantity), and so contribute less than 10 cents per liter to prepared microemulsion ink with a 5% surfactant concentration.
Other suitable ethoxylated alkyl phenols include those listed in the following table:
______________________________________Trivial name Formula HLB Cloud point______________________________________Nonoxynol-9 C9 H19 C4 H6 (CH2 CH2 O).sub..about .9 OH 13 54° C.Nonoxynol-10 C9 H19 C4 H6 (CH2 CH2 O).sub..about .10 OH 13.2 62° C.Nonoxynol-11 C9 H19 C4 H6 (CH2 CH2 O).sub..about .11 OH 13.8 72° C.Nonoxynol-12 C9 H19 C4 H6 (CH2 CH2 O).sub..about .12 OH 14.5 81° C.Octoxynol-9 C8 H17 C4 H6 (CH2 CH2 O).sub..about .9 OH 12.1 61° C.Octoxynol-10 C8 H17 C4 H6 (CH2 CH2 O).sub..about .10 OH 13.6 65° C.Octoxynol-12 C8 H17 C4 H6 (CH2 CH2 O).sub..about .12 OH 14.6 88° C.Dodoxynol-10 C12 H25 C4 H6 (CH2 CH2 O).sub..abou t.10 OH 12.6 42° C.Dodoxynol-11 C12 H25 C4 H6 (CH2 CH2 O).sub..abou t.11 OH 13.5 56° C.Dodoxynol-14 C12 H25 C4 H6 (CH2 CH2 O).sub..abou t.14 OH 14.5 87° C.______________________________________
Microemulsion based inks have advantages other than surface tension control:
1) Microemulsions are thermodynamically stable, and will not separate. Therefore, the storage time can be very long. This is especially significant for office and portable printers, which may be used sporadically.
2) The microemulsion will form spontaneously with a particular drop size, and does not require extensive stirring, centrifuging, or filtering to ensure a particular range of emulsified oil drop sizes.
3) The amount of oil contained in the ink can be quite high, so dyes which are soluble in oil or soluble in water, or both, can be used. It is also possible to use a mixture of dyes, one soluble in water, and the other soluble in oil, to obtain specific colors.
4) Oil miscible pigments are prevented from flocculating, as they are trapped in the oil microdroplets.
5) The use of a microemulsion can reduce the mixing of different dye colors on the surface of the print medium.
6) The viscosity of microemulsions is very low.
7) The requirement for humectants can be reduced or eliminated.
Dyes and pigments in microemulsion based inks
Oil in water mixtures can have high oil contents--as high as 40%--and still form O/W microemulsions. This allows a high dye or pigment loading.
Mixtures of dyes and pigments can be used. An example of a microemulsion based ink mixture with both dye and pigment is as follows:
1) 70% water
2) 5% water soluble dye
3) 5% surfactant
4) 10% oil
5) 10% oil miscible pigment
The following table shows the nine basic combinations of colorants in the oil and water phases of the microemulsion that may be used.
______________________________________Combination Colorant in water phase Colorant in oil phase______________________________________1 none oil miscible pigment2 none oil soluble dye3 water soluble dye none4 water soluble dye oil miscible pigment5 water soluble dye oil soluble dye6 pigment dispersed in water none7 pigment dispersed in water oil miscible pigment8 pigment dispersed in water oil soluble dye9 none none______________________________________
The ninth combination, with no colorants, is useful for printing transparent coatings, UV ink, and selective gloss highlights.
As many dyes are amphiphilic, large quantities of dyes can also be solubilized in the oil-water boundary layer as this layer has a very large surface area.
It is also possible to have multiple dyes or pigments in each phase, and to have a mixture of dyes and pigments in each phase.
When using multiple dyes or pigments the absorption spectrum of the resultant ink will be the weighted average of the absorption spectra of the different colorants used. This presents two problems:
1) The absorption spectrum will tend to become broader, as the absorption peaks of both colorants are averaged. This has a tendency to `muddy` the colors. To obtain brilliant color, careful choice of dyes and pigments based on their absorption spectra, not just their human-perceptible color, needs to be made.
2) The color of the ink may be different on different substrates. If a dye and a pigment are used in combination, the color of the dye will tend to have a smaller contribution to the printed ink color on more absorptive papers, as the dye will be absorbed into the paper, while the pigment will tend to `sit on top` of the paper. This may be used as an advantage in some circumstances.
Surfactants with a Krafft point in the drop selection temperature range
For ionic surfactants there is a temperature (the Krafft point) below which the solubility is quite low, and the solution contains essentially no micelles. Above the Krafft temperature micelle formation becomes possible and there is a rapid increase in solubility of the surfactant. If the critical micelle concentration (CMC) exceeds the solubility of a surfactant at a particular temperature, then the minimum surface tension will be achieved at the point of maximum solubility, rather than at the CMC. Surfactants are usually much less effective below the Krafft point.
This factor can be used to achieve an increased reduction in surface tension with increasing temperature. At ambient temperatures, only a portion of the surfactant is in solution. When the nozzle heater is turned on, the temperature rises, and more of the surfactant goes into solution, decreasing the surface tension.
A surfactant should be chosen with a Krafft point which is near the top of the range of temperatures to which the ink is raised. This gives a maximum margin between the concentration of surfactant in solution at ambient temperatures, and the concentration of surfactant in solution at the drop selection temperature.
The concentration of surfactant should be approximately equal to the CMC at the Krafft point. In this manner, the surface tension is reduced to the maximum amount at elevated temperatures, and is reduced to a minimum amount at ambient temperatures.
The following table shows some commercially available surfactants with Krafft points in the desired range.
______________________________________Formula Krafft point______________________________________C16 H33 SO3 - Na+ 57° C.C18 H37 SO3 - Na+ 70° C.C16 H33 SO4 - Na+ 45° C.Na+- O4 S(CH2)16 SO4 - Na+ 44.9° C.K+- O4 S(CH2)16 SO4 - K+ 55° C.C16 H33 CH(CH3)C4 H6 SO3 - Na+ 60.8° C.______________________________________
Surfactants with a cloud point in the drop selection temperature range
Non-ionic surfactants using polyoxyethylene (POE) chains can be used to create an ink where the surface tension falls with increasing temperature. At low temperatures, the POE chain is hydrophilic, and maintains the surfactant in solution. As the temperature increases, the structured water around the POE section of the molecule is disrupted, and the POE section becomes hydrophobic. The surfactant is increasingly rejected by the water at higher temperatures, resulting in increasing concentration of surfactant at the air/ink interface, thereby lowering surface tension. The temperature at which the POE section of a nonionic surfactant becomes hydrophilic is related to the cloud point of that surfactant. POE chains by themselves are not particularly suitable, as the cloud point is generally above 100° C.
Polyoxypropylene (POP) can be combined with POE in POE/POP block copolymers to lower the cloud point of POE chains without introducing a strong hydrophobicity at low temperatures.
Two main configurations of symmetrical POE/POP block copolymers are available. These are:
1) Surfactants with POE segments at the ends of the molecules, and a POP segment in the centre, such as the poloxamer class of surfactants (generically CAS 9003-11-6)
2) Surfactants with POP segments at the ends of the molecules, and a POE segment in the centre, such as the meroxapol class of surfactants (generically also CAS 9003-11-6)
Some commercially available varieties of poloxamer and meroxapol with a high surface tension at room temperature, combined with a cloud point above 40° C. and below 100° C. are shown in the following table:
______________________________________ Surface BASF Trade Tension CloudTrivial name name Formula (mN/m) point______________________________________Meroxapol Pluronic HO(CHCH3 CH2 O).sub.˜7 -- 50.9 69° C.105 10R5 (CH2 CH2 O).sub.˜22 -- (CHCH3 CH2 O).sub.˜7 OHMeroxapol Pluronic HO(CHCH3 CH2 O).sub.˜7 -- 54.1 99° C.108 10R8 (CH2 CH2 O).sub.˜91 -- (CHCH3 CH2 O).sub.˜7 OHMeroxapol Pluronic HO(CHCH3 CH2 O).sub.˜12 -- 47.3 81° C.178 17R8 (CH2 CH2 O).sub.˜136 -- (CHCH3 CH2 O).sub.˜12 OHMeroxapol Pluronic HO(CHCH3 CH2 O).sub.˜18 -- 46.1 80° C.258 25R8 (CH2 CH2 O).sub.˜163 -- (CHCH3 CH2 O).sub.˜18 OHPoloxamer Pluronic L35 HO(CH2 CH2 O).sub.˜11 -- 48.8 77° C.105 (CHCH3 CH2 O).sub.˜16 -- (CH2 CH2 O).sub.˜11 OHPoloxamer Pluronic L44 HO(CH2 CH2 O).sub.˜11 -- 45.3 65° C.124 (CHCH3 CH2 O).sub.˜21 -- (CH2 CH2 O).sub.˜11 OH______________________________________
Other varieties of poloxamer and meroxapol can readily be synthesized using well known techniques. Desirable characteristics are a room temperature surface tension which is as high as possible, and a cloud point between 40° C. and 100° C., and preferably between 60° C. and 80° C.
Meroxapol HO(CHCH3 CH2 O)x (CH2 CH2 O)y (CHCH3 CH2 O)z OH! varieties where the average x and z are approximately 4, and the average y is approximately 15 may be suitable.
If salts are used to increase the electrical conductivity of the ink, then the effect of this salt on the cloud point of the surfactant should be considered.
The cloud point of POE surfactants is increased by ions that disrupt water structure (such as I-), as this makes more water molecules available to form hydrogen bonds with the POE oxygen lone pairs. The cloud point of POE surfactants is decreased by ions that form water structure (such as Cl-, O-), as fewer water molecules are available to form hydrogen bonds. Bromide ions have relatively little effect. The ink composition can be `tuned` for a desired temperature range by altering the lengths of POE and POP chains in a block copolymer surfactant, and by changing the choice of salts (e.g Cl- to Br- to I-) that are added to increase electrical conductivity. NaCl is likely to be the best choice of salts to increase ink conductivity, due to low cost and non-toxicity. NaCl slightly lowers the cloud point of nonionic surfactants.
Hot Melt Inks
The ink need not be in a liquid state at room temperature. Solid `hot melt` inks can be used by heating the printing head and ink reservoir above the melting point of the ink. The hot melt ink must be formulated so that the surface tension of the molten ink decreases with temperature. A decrease of approximately 2 mN/m will be typical of many such preparations using waxes and other substances. However, a reduction in surface tension of approximately 20 mN/m is desirable in order to achieve good operating margins when relying on a reduction in surface tension rather than a reduction in viscosity.
The temperature difference between quiescent temperature and drop selection temperature may be greater for a hot melt ink than for a water based ink, as water based inks are constrained by the boiling point of the water.
The ink must be liquid at the quiescent temperature. The quiescent temperature should be higher than the highest ambient temperature likely to be encountered by the printed page. The quiescent temperature should also be as low as practical, to reduce the power needed to heat the print head, and to provide a maximum margin between the quiescent and the drop ejection temperatures. A quiescent temperature between 60° C. and 90° C. is generally suitable, though other temperatures may be used. A drop ejection temperature of between 160° C. and 200° C. is generally suitable.
There are several methods of achieving an enhanced reduction in surface tension with increasing temperature.
1) A dispersion of microfine particles of a surfactant with a melting point substantially above the quiescent temperature, but substantially below the drop ejection temperature, can be added to the hot melt ink while in the liquid phase.
2) A polar/non-polar microemulsion with a PIT which is preferably at least 20° C. above the melting points of both the polar and non-polar compounds.
To achieve a large reduction in surface tension with temperature, it is desirable that the hot melt ink carrier have a relatively large surface tension (above 30 mN/m) when at the quiescent temperature. This generally excludes alkanes such as waxes. Suitable materials will generally have a strong intermolecular attraction, which may be achieved by multiple hydrogen bonds, for example, polyols, such as Hexanetetrol, which has a melting point of 88° C.
Surface tension reduction of various solutions
FIG. 3(d) shows the measured effect of temperature on the surface tension of various aqueous preparations containing the following additives:
1) 0.1% sol of Stearic Acid
2) 0.1% sol of Palmitic acid
3) 0.1% solution of Pluronic 10R5 (trade mark of BASF)
4) 0.1% solution of Pluronic L35 (trade mark of BASF)
5) 0.1% solution of Pluronic L44 (trade mark of BASF)
Operation Using Reduction of Viscosity
As a second example, operation of an embodiment using thermal reduction of viscosity and proximity drop separation, in combination with hot melt ink, is as follows. Prior to operation of the printer, solid ink is melted in the reservoir 64. The reservoir, ink passage to the print head, ink channels 75, and print head 50 are maintained at a temperature at which the ink 100 is liquid, but exhibits a relatively high viscosity (for example, approximately 100 cP). The Ink 100 is retained in the nozzle by the surface tension of the ink. The ink 100 is formulated so that the viscosity of the ink reduces with increasing temperature. The ink pressure oscillates at a frequency which is an integral multiple of the drop ejection frequency from the nozzle. The ink pressure oscillation causes oscillations of the ink meniscus at the nozzle tips, but this oscillation is small due to the high ink viscosity. At the normal operating temperature, these oscillations are of insufficient amplitude to result in drop separation. When the heater 103 is energized, the ink forming the selected drop is heated, causing a reduction in viscosity to a value which is preferably less than 5 cP. The reduced viscosity results in the ink meniscus moving further during the high pressure part of the ink pressure cycle. The recording medium 51 is arranged sufficiently close to the print head 50 so that the selected drops contact the recording medium 51, but sufficiently far away that the unselected drops do not contact the recording medium 51. Upon contact with the recording medium 51, part of the selected drop freezes, and attaches to the recording medium. As the ink pressure falls, ink begins to move back into the nozzle. The body of ink separates from the ink which is frozen onto the recording medium. The meniscus of the ink 100 at the nozzle tip then returns to low amplitude oscillation. The viscosity of the ink increases to its quiescent level as remaining heat is dissipated to the bulk ink and print head. One ink drop is selected, separated and forms a spot on the recording medium 51 for each heat pulse. As the heat pulses are electrically controlled, drop on demand ink jet operation can be achieved.
Image Processing for Print Heads
An objective of printing systems according to the invention is to attain a print quality which is equal to that which people are accustomed to in quality color publications printed using offset printing. This can be achieved using a print resolution of approximately 1,600 dpi. However, 1,600 dpi printing is difficult and expensive to achieve. Similar results can be achieved using 800 dpi printing, with 2 bits per pixel for cyan and magenta, and one bit per pixel for yellow and black This color model is herein called CC'MM'YK. Where high quality monochrome image printing is also required, two bits per pixel can also be used for black. This color model is herein called CC'MM'YKK'.
Applications Using Print Heads According to this Invention
Printing apparatus and methods of this invention are suitable for a wide range of applications, including (but not limited to) the following: color and monochrome office printing, short run digital printing, high speed digital printing, process color printing, spot color printing, offset press supplemental printing, low cost printers using scanning print heads, high speed printers using pagewidth print heads, portable color and monochrome printers, color and monochrome copiers, color and monochrome facsimile machines, combined printer, facsimile and copying machines, label printing, large format plotters, photographic duplication, printers for digital photographic processing, portable printers incorporated into digital `instant` cameras, video printing, printing of PhotoCD images, portable printers for `Personal Digital Assistants`, wallpaper printing, indoor sign printing, billboard printing, and fabric printing.
Compensation of Print Heads for Environmental Conditions
It is desirable that drop on demand printing systems have consistent and predictable ink drop size and position. Unwanted variation in ink drop size and position causes variations in the optical density of the resultant print, reducing the perceived print quality. These variations should be kept to a small proportion of the nominal ink drop volume and pixel spacing respectively. Many environmental variables can be compensated to reduce their effect to insignificant levels. Active compensation of some factors can be achieved by varying the power applied to the nozzle heaters.
An optimum temperature profile for one print head embodiment involves an instantaneous raising of the active region of the nozzle tip to the ejection temperature, maintenance of this region at the ejection temperature for the duration of the pulse, and instantaneous cooling of the region to the ambient temperature.
This optimum is not achievable due to the stored heat capacities and thermal conductivities of the various materials used in the fabrication of the nozzles in accordance with the invention. However, improved performance can be achieved by shaping the power pulse using curves which can be derived by iterative refinement of finite element simulation of the print head. The power applied to the heater can be varied in time by various techniques, including, but not limited to:
1) Varying the voltage applied to the heater
2) Modulating the width of a series of short pulses (PWM)
3) Modulating the frequency of a series of short pulses (PFM)
To obtain accurate results, a transient fluid dynamic simulation with free surface modeling is required, as convection in the ink, and ink flow, significantly affect on the temperature achieved with a specific power curve.
By the incorporation of appropriate digital circuitry on the print head substrate, it is practical to individually control the power applied to each nozzle.
One way to achieve this is by `broadcasting` a variety of different digital pulse trains across the print head chip, and selecting the appropriate pulse train for each nozzle using multiplexing circuits.
An example of the environmental factors which may be compensated for is listed in the table "Compensation for environmental factors". This table identifies which environmental factors are best compensated globally (for the entire print head), per chip (for each chip in a composite multi-chip print head), and per nozzle.
______________________________________Compensation for environmental factorsFactor Sensing or user Compensationcompensated Scope control method mechanism______________________________________Ambient Global Temperature sensor Power supply voltageTemperature mounted on print or global PFM patterns headPower supply Global Predictive active Power supply voltagevoltage fluctua- nozzle count based or global PFM patternstion with number on print dataof active nozzlesLocal heat build- Per Predictive active Selection ofup with nozzle nozzle count based appropriate PFMsuccessive nozzle on print data pattern for eachactuation printed dropDrop size control Per Image data Selection offor multiple bits nozzle appropriate PFMper pixel pattern for each printed dropNozzle geometry Per Factory measure- Global PFM patternsvariations chip ment, datafile per print head chipbetween wafers supplied with print headHeater resistivity Per Factory measure- Global PFM patternsvariations chip ment, datafile per print head chipbetween wafers supplied with print headUser image Global User selection Power supply voltage,intensity electrostaticadjustment acceleration voltage, or ink pressureInk surface Global Ink cartridge sensor Global PFM patternstension reduction or user selectionmethod andthresholdtemperatureInk viscosity Global Ink cartridge sensor Global PFM patterns or user selection and/or clock rateInk dye or Global Ink cartridge sensor Global PFM patternspigment or user selectionconcentrationInk response time Global Ink cartridge sensor Global PFM patterns or user selection______________________________________
Most applications will not require compensation for all of these variables. Some variables have a minor effect, and compensation is only necessary where very high image quality is required.
Print head drive circuits
FIG. 4 is a block schematic diagram showing electronic operation of an example head driver circuit in accordance with this invention. This control circuit uses analog modulation of the power supply voltage applied to the print head to achieve heater power modulation, and does not have individual control of the power applied to each nozzle. FIG. 4 shows a block diagram for a system using an 800 dpi pagewidth print head which prints process color using the CC'MM'YK color model. The print head 50 has a total of 79,488 nozzles, with 39,744 main nozzles and 39,744 redundant nozzles. The main and redundant nozzles are divided into six colors, and each color is divided into 8 drive phases. Each drive phase has a shift register which converts the serial data from a head control ASIC 400 into parallel data for enabling heater drive circuits. There is a total of 96 shift registers, each providing data for 828 nozzles. Each shift register is composed of 828 shift register stages 217, the outputs of which are logically anded with phase enable signal by a nand gate 215. The output of the nand gate 215 drives an inverting buffer 216, which in turn controls the drive transistor 201. The drive transistor 201 actuates the electrothermal heater 200, which may be a heater 103 as shown in FIG. 1(b). To maintain the shifted data valid during the enable pulse, the clock to the shift register is stopped the enable pulse is active by a clock stopper 218, which is shown as a single gate for clarity, but is preferably any of a range of well known glitch free clock control circuits. Stopping the clock of the shift register removes the requirement for a parallel data latch in the print head, but adds some complexity to the control circuits in the Head Control ASIC 400. Data is routed to either the main nozzles or the redundant nozzles by the data router 219 depending on the state of the appropriate signal of the fault status bus.
The print head shown in FIG. 4 is simplified, and does not show various means of improving manufacturing yield, such as block fault tolerance. Drive circuits for different configurations of print head can readily be derived from the apparatus disclosed herein.
Digital information representing patterns of dots to be printed on the recording medium is stored in the Page or Band memory 1513, which may be the same as the Image memory 72 in FIG. 1(a). Data in 32 bit words representing dots of one color is read from the Page or Band memory 1513 using addresses selected by the address mux 417 and control signals generated by the Memory Interface 418. These addresses are generated by Address generators 411, which forms part of the `Per color circuits` 410, for which there is one for each of the six color components. The addresses are generated based on the positions of the nozzles in relation to the print medium. As the relative position of the nozzles may be different for different print heads, the Address generators 411 are preferably made programmable. The Address generators 411 normally generate the address corresponding to the position of the main nozzles. However, when faulty nozzles are present, locations of blocks of nozzles containing faults can be marked in the Fault Map RAM 412. The Fault Map RAM 412 is read as the page is printed. If the memory indicates a fault in the block of nozzles, the address is altered so that the Address generators 411 generate the address corresponding to the position of the redundant nozzles. Data read from the Page or Band memory 1513 is latched by the latch 413 and converted to four sequential bytes by the multiplexer 414. Timing of these bytes is adjusted to match that of data representing other colors by the FIFO 415. This data is then buffered by the buffer 430 to form the 48 bit main data bus to the print head 50. The data is buffered as the print head may be located a relatively long distance from the head control ASIC. Data from the Fault Map RAM 412 also forms the input to the FIFO 416. The timing of this data is matched to the data output of the FIFO 415, and buffered by the buffer 431 to form the fault status bus.
The programmable power supply 320 provides power for the head 50. The voltage of the power supply 320 is controlled by the DAC 313, which is part of a RAM and DAC combination (RAMDAC) 316. The RAMDAC 316 contains a dual port RAM 317. The contents of the dual port RAM 317 are programmed by the Microcontroller 315. Temperature is compensated by changing the contents of the dual port RAM 317. These values are calculated by the microcontroller 315 based on temperature sensed by a thermal sensor 300. The thermal sensor 300 signal connects to the Analog to Digital Converter (ADC) 311. The ADC 311 is preferably incorporated in the Microcontroller 315.
The Head Control ASIC 400 contains control circuits for thermal lag compensation and print density. Thermal lag compensation requires that the power supply voltage to the head 50 is a rapidly time-varying voltage which is synchronized with the enable pulse for the heater. This is achieved by programming the programmable power supply 320 to produce this voltage. An analog time varying programming voltage is produced by the DAC 313 based upon data read from the dual port RAM 317. The data is read according to an address produced by the counter 403. The counter 403 produces one complete cycle of addresses during the period of one enable pulse. This synchronization is ensured, as the counter 403 is clocked by the system clock 408, and the top count of the counter 403 is used to clock the enable counter 404. The count from the enable counter 404 is then decoded by the decoder 405 and buffered by the buffer 432 to produce the enable pulses for the head 50. The counter 403 may include a prescaler if the number of states in the count is less than the number of clock periods in one enable pulse. Sixteen voltage states are adequate to accurately compensate for the heater thermal lag. These sixteen states can be specified by using a four bit connection between the counter 403 and the dual port RAM 317. However, these sixteen states may not be linearly spaced in time. To allow non-linear timing of these states the counter 403 may also include a ROM or other device which causes the counter 403 to count in a non-linear fashion. Alternatively, fewer than sixteen states may be used.
For print density compensation, the printing density is detected by counting the number of pixels to which a drop is to be printed (`on` pixels) in each enable period. The `on` pixels are counted by the On pixel counters 402. There is one On pixel counter 402 for each of the eight enable phases. The number of enable phases in a print head in accordance with the invention depend upon the specific design. Four, eight, and sixteen are convenient numbers, though there is no requirement that the number of enable phases is a power of two. The On Pixel Counters 402 can be composed of combinatorial logic pixel counters 420 which determine how many bits in a nibble of data are on. This number is then accumulated by the adder 421 and accumulator 422. A latch 423 holds the accumulated value valid for the duration of the enable pulse. The multiplexer 401 selects the output of the latch 423 which corresponds to the current enable phase, as determined by the enable counter 404. The output of the multiplexer 401 forms part of the address of the dual port RAM 317. An exact count of the number of `on` pixels is not necessary, and the most significant four bits of this count are adequate.
Combining the four bits of thermal lag compensation address and the four bits of print density compensation address means that the dual port RAM 317 has an 8 bit address. This means that the dual port RAM 317 contains 256 numbers, which are in a two dimensional array. These two dimensions are time (for thermal lag compensation) and print density. A third dimension--temperature--can be included. As the ambient temperature of the head varies only slowly, the microcontroller 315 has sufficient time to calculate a matrix of 256 numbers compensating for thermal lag and print density at the current temperature. Periodically (for example, a few times a second), the microcontroller senses the current head temperature and calculates this matrix.
The clock to the print head 50 is generated from the system clock 408 by the Head clock generator 407, and buffered by the buffer 406. To facilitate testing of the Head control ASIC, JTAG test circuits 499 may be included.
Comparison with thermal ink jet technology
The table "Comparison between Thermal ink jet and Present Invention" compares the aspects of printing in accordance with the present invention with thermal ink jet printing technology.
A direct comparison is made between the present invention and thermal ink jet technology because both are drop on demand systems which operate using thermal actuators and liquid ink. Although they may appear similar, the two technologies operate on different principles.
Thermal ink jet printers use the following fundamental operating principle. A thermal impulse caused by electrical resistance heating results in the explosive formation of a bubble in liquid ink. Rapid and consistent bubble formation can be achieved by superheating the ink, so that sufficient heat is transferred to the ink before bubble nucleation is complete. For water based ink, ink temperatures of approximately 280° C. to 400° C. are required. The bubble formation causes a pressure wave which forces a drop of ink from the aperture with high velocity. The bubble then collapses, drawing ink from the ink reservoir to re-fill the nozzle. Thermal ink jet printing has been highly successful commercially due to the high nozzle packing density and the use of well established integrated circuit manufacturing techniques. However, thermal ink jet printing technology faces significant technical problems including multi-part precision fabrication, device yield, image resolution, `pepper` noise, printing speed, drive transistor power, waste power dissipation, satellite drop formation, thermal stress, differential thermal expansion, kogation, cavitation, rectified diffusion, and difficulties in ink formulation.
Printing in accordance with the present invention has many of the advantages of thermal ink jet printing, and completely or substantially eliminates many of the inherent problems of thermal ink jet technology.
______________________________________Comparison between Thermal ink jet and Present Invention Thermal Ink-Jet Present Invention______________________________________Drop selection Drop ejected by pressure Choice of surface tensionmechanism wave caused by thermally or viscosity reduction induced bubble mechanismsDrop separation Same as drop selection Choice of proximity,mechanism mechanism electrostatic, magnetic, and other methodsBasic ink carrier Water Water, microemulsion, alcohol, glycol, or hot meltHead construction Precision assembly of Monolithic nozzle plate, ink channel, and substratePer copy printing Very high due to limited Can be low due tocost print head life and permanent print heads expensive inks and wide range of possible inksSatellite drop Significant problem which No satellite dropformation degrades image quality formationOperating ink 280° C. to 400° C. (high Approx. 70° C. (dependstemperature temperature limits dye use upon ink formulation) and ink formulation)Peak heater 400° C. to 1,000° C. (high Approx. 130° C.temperature temperature reduces device life)Cavitation (heater Serious problem limiting None (no bubbles areerosion by bubble head life formed)collapse)Kogation (coating Serious problem limiting None (water based inkof heater by ink head life and ink temperature does notash) formulation exceed 100° C.)Rectified Serious problem limiting Does not occur as the inkdiffusion ink formulation pressure does not go(formation of negativeink bubbles dueto pressurecycles)Resonance Serious problem limiting Very small effect as nozzle design and pressure waves are small repetition ratePractical Approx. 800 dpi max. Approx. 1,600 dpi max.resolutionSelf-cooling No (high energy required) Yes: printed ink carriesoperation away drop selection energyDrop ejection High (approx. 10 m/sec) Low (approx. 1 m/sec)velocityCrosstalk Serious problem requiring Low velocities and careful acoustic design, pressures associated with which limits nozzle refill drop ejection make rate. crosstalk very small;Operating thermal Serious problem limiting Low: maximum tempera-stress print-head life. ture increase approx. 90° C. at centre of heater.Manufacturing Serious problem limiting Same as standard CMOSthermal stress print-head size. manufacturing process.Drop selection Approx. 20 μJ Approx. 270 nJenergyHeater pulse Approx. 2-3 μs Approx. 15-30 μsperiodAverage heater Approx. 8 Watts per Approx. 12 mW perpulse power heater. heater. This is more than 500 times less than Thermal Ink-Jet.Heater pulse Typically approx. 40 V. Approx. 5 to 10 V.voltageHeater peak pulse Typically approx. 200 mA Approx. 4 mA percurrent per heater. This requires heater. This allows the bipolar or very large MOS use of small MOS drive transistors. drive transistors.Fault tolerance Not implemented. Not Simple implementation practical for edge results in better shooter type. yield and reliabilityConstraints on Many constraints Temperature coefficientink composition including kogation, of surface tension or nucleation, etc. viscosity must be negative.Ink pressure Atmospheric pressure or Approx. 1.1 atm lessIntegrated drive Bipolar circuitry usually CMOS, nMOS,or bipolarcircuitry required due to high drive currentDifferential Significant problem for Monolithic constructionthermal expansion large print heads reduces problemPagewidth print Major problems with yield, High yield, low cost andheads cost, precision long life due to fault construction, head life, and tolerance. Self cooling power dissipation due to low power dissipation.______________________________________
Yield and Fault Tolerance
In most cases, monolithic integrated circuits cannot be repaired if they are not completely functional when manufactured. The percentage of operational devices which are produced from a wafer run is known as the yield. Yield has a direct influence on manufacturing cost. A device with a yield of 5% is effectively ten times more expensive to manufacture than an identical device with a yield of 50%.
There are three major yield measurements:
1) Fab yield
2) Wafer sort yield
3) Final test yield
For large die, it is typically the wafer sort yield which is the most serious limitation on total yield. Full pagewidth color heads in accordance with this invention are very large in comparison with typical VLSI circuits. Good wafer sort yield is critical to the cost-effective manufacture of such heads.
FIG. 5 is a graph of wafer sort yield versus defect density for a monolithic full width color A4 head embodiment of the invention. The head is 215 mm long by 5 mm wide. The non fault tolerant yield 198 is calculated according to Murphy's method, which is a widely used yield prediction method. With a defect density of one defect per square cm, Murphy's method predicts a yield less than 1%. This means that more than 99% of heads fabricated would have to be discarded. This low yield is highly undesirable, as the print head manufacturing cost becomes unacceptably high.
Murphy's method approximates the effect of an uneven distribution of defects. FIG. 5 also includes a graph of non fault tolerant yield 197 which explicitly models the clustering of defects by introducing a defect clustering factor. The defect clustering factor is not a controllable parameter in manufacturing, but is a characteristic of the manufacturing process. The defect clustering factor for manufacturing processes can be expected to be approximately 2, in which case yield projections closely match Murphy's method.
A solution to the problem of low yield is to incorporate fault tolerance by including redundant functional units on the chip which are used to replace faulty functional units.
In memory chips and most Wafer Scale Integration (WSI) devices, the physical location of redundant sub-units on the chip is not important. However, in printing heads the redundant sub-unit may contain one or more printing actuators. These must have a fixed spatial relationship to the page being printed. To be able to print a dot in the same position as a faulty actuator, redundant actuators must not be displaced in the non-scan direction. However, faulty actuators can be replaced with redundant actuators which are displaced in the scan direction. To ensure that the redundant actuator prints the dot in the same position as the faulty actuator, the data timing to the redundant actuator can be altered to compensate for the displacement in the scan direction.
To allow replacement of all nozzles, there must be a complete set of spare nozzles, which results in 100% redundancy. The requirement for 100% redundancy would normally more than double the chip area, dramatically reducing the primary yield before substituting redundant units, and thus eliminating most of the advantages of fault tolerance.
However, with print head embodiments according to this invention, the minimum physical dimensions of the head chip are determined by the width of the page being printed, the fragility of the head chip, and manufacturing constraints on fabrication of ink channels which supply ink to the back surface of the chip. The minimum practical size for a full width, full color head for printing A4 size paper is approximately 215 mm×5 mm. This size allows the inclusion of 100% redundancy without significantly increasing chip area, when using 1.5 μm CMOS fabrication technology. Therefore, a high level of fault tolerance can be included without significantly decreasing primary yield.
When fault tolerance is included in a device, standard yield equations cannot be used. Instead, the mechanisms and degree of fault tolerance must be specifically analyzed and included in the yield equation. FIG. 5 shows the fault tolerant sort yield 199 for a full width color A4 head which includes various forms of fault tolerance, the modeling of which has been included in the yield equation. This graph shows projected yield as a function of both defect density and defect clustering. The yield projection shown in FIG. 5 indicates that thoroughly implemented fault tolerance can increase wafer sort yield from under 1% to more than 90% under identical manufacturing conditions. This can reduce the manufacturing cost by a factor of 100.
Portable printers using concurrent drop selection and drop separation print heads
The table "Example product specifications," shows the specifications of one possible configuration of a portable color printer for use with notebook PC's and other computer systems.
______________________________________Example product specificationsConfiguration Portable______________________________________Printer type Full width printing headNumber of nozzles 19,840 active nozzles, 19,840 spare nozzlesPaper size A4, US LetterPrinting speed 1 second + paper transport + image calculation timePrinter resolution 600 dpi, digitally halftonedPaper volume 20 sheet feederDimensions (W × D × H) Approx. 320 × 230 × 45 mmPage description language Adobe Postscript* level 2, PCL5*Connectivity LocalTalk*, Centronics*, Ethernet 10BaseT______________________________________ *`Postscript` is a registered trademark of Adobe Systems Incorporated, `PCL5` is a trademark of HewlettPackard Corporation, `LocalTalk` is a trademark of Apple Computer Inc., `Centronics` is a trademark of Centronics Inc.
The table "LIFT head type A4-4-600" is a summary of some characteristics of an example full color monolithic printing head capable of printing an color A4 page at 600 dpi in one second.
FIG. 6 shows a schematic process diagram of a portable color printer using a printing head according to the present invention. The blocks in this diagram represent discrete functions, irrespective of their implementations. Some of the blocks are electronic hardware, some are computer software, some are electromechanical units, and some are mechanical units. Some of the blocks are subsystems, which may include electronic hardware, software, mechanics, and optics.
A computer interface 513 provides a data connection to a computer. The computer interface may be a parallel interface such as SCSI or GPIB, or a serial interface such as RS232 or RS422. The computer interface may also be a network interface such as Ethernet. It also could be a non-standard interface, though this is generally not beneficial for the market. The computer interface is required so that the computer can send Page Description Language information to the printer.
There are several Page Description Languages (PDLs) in common use. These include Adobe's PostScript language and Hewlett Packard's PCL5. The printer can either support a single PDL, or automatic PDL selector can detect the PDL being used from the data stream, and send the PDL data to an appropriate PDL interpreter.
The PDL interpreter can interpret a scan-line rendering PDL. Such interpreters can create the page image in scan-line order, without reference to a frame memory. The continuous tone data can be produced in raster order, so may be error diffused before being stored in the bi-level image memory 505. In the case of a 600 dpi, A4 color, the Bi-level page memory 505 requires approximately 16 MBytes. This can be implemented in DRAM. The Bi-level page memory may be a section of the main memory of the main system processor. The functions of the main system processor are primarily to interpret the PDL. The main system processor may also perform the digital halftoning. Alternatively, this may be performed by digital hardware in the form of an ASIC. However, this function is relatively simple when compared to the PDL interpretation, and can readily be performed by the processor.
PDL interpreters which require random access to a page memory cannot use error diffusion as a means of halftoning, as error diffusion requires access to the continuous tone information in scan-line order. A practical solution is to use ordered dithering instead of error diffusion. The digital halftoning unit 515 converts continuous tone data in arbitrary order from the PDL interpreter 514 using a dispersed dot ordered dither. The dithered results are then stored in the bi-level page memory. PDL interpreters in current use typically use a clustered dot ordered dither to reduce the effects of non-linear dot addition that occurs with laser printers and offset printing. However, dot addition using the concurrent drop selection and drop separation printing process is substantially linear when using coated paper, so dispersed dot ordered dithering can be used. Computer optimized stochastic dispersed dot ordered dither provides a substantially better image quality than clustered dot ordered dither.
When a page is to be printed, the Bi-level page memory 505 is read in real-time. This data is then processed by the data phasing and fault tolerance system 506. This unit provides the appropriate delays to synchronize the print data with the offset positions of the nozzle of the printing head. It also provides alternate data paths for fault tolerance, to compensate for blocked nozzles, faulty nozzles or faulty circuits in the head.
The monolithic printing head 50 prints the image 60 composed of a multitude of ink drops onto a recording medium 51. This medium will typically be paper, but can also be overhead transparency film, cloth, or most other substantially flat surfaces which will accept ink drops.
The bi-level image processed by the data phasing and fault tolerance circuit 506 provides the pixel data in the correct sequence to the data shift registers 56. Data sequencing is required to compensate for the nozzle arrangement and the movement of the paper. When the data has been loaded into the shift registers, it is presented in parallel to the heater driver circuits 57. At the correct time, these driver circuits will electronically connect the corresponding heaters 58 with the voltage pulse generated by the pulse shaper circuit 61 and the voltage regulator 62. The heaters 58 heat the tip of the nozzles 59, reducing the attraction of the ink to the nozzle surface material. Ink drops 60 escape from the nozzles in a pattern which corresponds to the digital impulses which have been applied to the heater driver circuits. The pressure of the ink in the nozzle is important, and the pressure in the ink reservoir 64 is regulated by the pressure regulator 63. The ink drops 60 fall under the influence of gravity or another field type towards the paper 51. During printing, the paper is continually moved relative to the print head by the paper transport system 65. As the print head is the full width of the paper used, it is only necessary to move the paper in one direction, and the print head can remain fixed.
The various subsystems are coordinated under the control of one or more control microcomputers 511, which also provide the user interface of the system. Alternatively, all control functions can be provided by the main system processor, which also executes the PDL interpreters and other software functions.
This printer system has many advantages over prior-art systems. Some of these advantages are high speed, high image quality, and small size. As no scanning elements are required, the printer can be built just slightly wider than the paper which it is to print on.
The production cost of this printer is also inherently much lower than other systems of comparable quality.
To obtain a system with even lower production cost, the page image can be rasterized by the external computer. In this case, the PDL interpreter 514 and digital halftoning 515 steps are performed by the host computer. If this is done, a high performance computer is no longer required as the main system processor in the printer, as no complex software tasks are required from it.
It is also possible to eliminate the bi-level page memory 505 from the printer if this function is performed by the host computer. In this case, a high speed interface between the host computer and the printer is required. If a printing speed of two seconds for a color 600 dpi A4 page is required, then the data must be transferred from the host computer at eight MBytes per second. This level of performance is readily achieved when the printer is connected to a portable computer which has a direct bus connection, or via a PC card (formerly PCMCIA card) interface.
There are many possible physical configurations of the invention. The smallest and most portable configuration is a rod shaped device, slightly longer than the width of the paper (A4 or US letter), and just thick enough and high enough to enclose the batteries, electronics, ink supply, ink pressure system, and paper transport system. With appropriate engineering, a fast, full color printer as small as 23 cm×4 cm×3 cm can be constructed. Such a miniature printer is suitable for some markets where light weight and small size are the most important characteristics.
A larger printer has several potential advantages:
1) Paper can be stored inside the printer
2) An automatic paper feeders can be incorporated
3) Larger ink supply can be incorporated
4) A higher capacity battery can be included
5) A larger circuit board can be included. With appropriate electronic design, this can result in faster operation.
6) Design and manufacturing constraints can be relaxed, which can result in lower manufacturing costs.
FIG. 7(a) shows a top view of the layout of major components for one possible configuration of such a printer. The main body of the printer includes an ink cartridge 920, a battery 930, a circuit board containing the control electronics 900, a full width print head 50, a paper pick-up roller 912, and paper transport rollers 65. External to the main body of the printer is an output paper tray 911.
FIG. 7(b) shows the same printer from side view. The input paper tray 910 is contained within the printer, and provides a convenient place to store blank paper when transporting the printer. When printing, sheets of blank paper 51 are grabbed by the paper pick-up roller 912 and passed to the paper transport rollers 65. The image is printed by the head 50, and ejected into the output paper tray 911. The detailed design of paper transport mechanisms is well known in the industry, and can be accomplished by engineers skilled in the art.
FIG. 8 shows a perspective view of the printer when opened. The output paper tray 911 folds over the body of the printer when not in use. When folded, the output paper tray 911 prevents the accidental activation of the printer by covering the control buttons 901.
Miniature portable color printers using concurrent drop selection and drop separation print heads
The table "Example product specifications," shows the specifications of one possible configuration of a portable color printer for use with notebook PC's and other computer systems.
______________________________________Example product specificationsConfiguration Portable______________________________________Printer type Full width printing headNumber of nozzles 19,840 active nozzles, 19,840 spare nozzlesPaper sizes A4, B4, B5, Letter, StatementPrinter resolution 600 dpi, digitally halftonedPaper feeder Manual sheet feederDimensions (W × D × H) Approx. 230 × 40 × 36 mmImage calculation Bit-map produced by computer: QuickDraw*, Microsoft GDI*Connectivity PC card slot or other high bandwidth connection______________________________________ *`QuickDraw`, QuickDraw GX, and Macintosh are a trademarks of Apple Computer Inc., `Windows` and `GDI` are trademarks of Microsoft Inc.
This print head is operated at lower than its maximum speed, as operation at full speed would require a data transfer rate of 16.4 MBytes per second across the data link between the notebook computer and the printer. Most notebook computers do not include external connections with this data capacity. However, many notebook computers currently have PCMCIA (Personal Computer Memory Card Industry Association) card slots. PCMCIA card slots provide a 16 bit wide parallel bus which can readily be operated in excess of 5 MHz. Thus data bandwidth using this interface can exceed 10 MBytes per second. However, this data rate needs to be sustained for a full 16 MBytes. Therefore, the data rate is derated to 4.1 MBytes per second, and the print time increased to 4 seconds.
FIG. 9 shows a schematic process diagram of a miniature portable color printer using a printing head according to the present invention. Page images created using various application software packages on the notebook computer are converted to bitmap images using various software running on the notebook computer. This software may be software that is incorporated into the operating system of the notebook computer, such as `QuickDraw` incorporated into `System 7` and other variations of the Macintosh operating system from Apple Computer Inc., or `GDI` (Graphics Device Interface} incorporated into Microsoft Windows operating system. The bitmap image may also be created by software interpreters of such page description languages as Adobe Postscript.
As the bitmapped page image is being created, it is stored in the Bi-level page memory 505. This memory will typically be part of the main memory of the notebook computer, and will typically be implemented in DRAM. Virtual memory implementations, with part of the bitmapped page image stored on a hard disk drive on the notebook computer will typically not be suitable. This is due to the low data bandwidth of most disk drives, which is below that required for the printer. In the case of a 600 dpi, A4 color, the Bi-level page memory 505 requires approximately 16 MBytes. At the time of writing, this is more memory than is typically installed in notebook computers. However, this much memory can be optionally installed into many notebook computers, and the average amount of memory installed in notebook computers is steadily rising.
When a page is to be printed, the Bi-level page memory 505 is read in real-time. This memory should be read by DMA (Direct Memory Access) unless the processor in the notebook computer can operate fast enough to supply a continuous data stream at 4.1 MBytes per second without interruption. The data is passed via a high speed computer interface to the printer. One external interface with adequate data bandwidth which is installed in a large number of notebook computers is a PCMCIA interface. However, any digital interface capable of sustaining a data transfer rate of 4.1 MBytes per second can be used.
This data is then processed by the data phasing and fault tolerance system 506. This unit provides the appropriate delays to synchronize the print data with the offset positions of the nozzle of the printing head. It also provides alternate data paths for fault tolerance, to compensate for blocked nozzles, faulty nozzles or faulty circuits in the head. The data phasing and fault tolerance system 506 requires a local buffer memory to store the data currently being used. The minimum size of the local buffer memory is 2,480 bytes, however, a local buffer memory size of 64 KBytes is recommended to simplify system design.
FIG. 10(a) shows a side view of the layout of major components for one possible configuration of such a printer. The main body of the printer includes an ink cartridge 920, a battery 930, a circuit board containing the control electronics 900, a full width print head 50, an ink channel device 75, paper or other printing medium 51, paper transport rollers 65, a smoothing device 68 and a paper guide 67. The battery 930 is composed of four `AA` type cells. FIG. 10(a) is enlarged by a factor of 2:1.
FIG. 10(b) shows the same printer from front view. Blank paper is fed to the printer from the front. An optical or mechanical sensor (not shown) senses that paper has been positioned at the input and starts the paper transport control system 66 which includes an electric motor for driving the paper rollers 65. The image is printed by the head 50, controlled by data from the notebook computer which is processed by the control electronics 900. Ink is forced from an ink cartridge 920 using pressure created by a pressure regulator 63 through tubing to an ink channel device 75. The ink channel device 75 provides liquid ink to the back surface of the head 50. The ink flows through the print head 50 under control of the bi-level page data to form the image from drops of ink 60, shown in FIG. 10(a).
FIG. 10(c) shows a top view of major component layout of the printer, with the control electronics 900 removed. Shown in this diagram are the 4 `AA` cells constituting the battery 930, the paper transport rollers 65, the ink channel device 75, the ink cartridge 920, the pressure regulator 63, and the paper transport control system 66.
These diagrams show the general principles of the operation of the printer. The detailed design of paper transport mechanisms is well known in the industry, and can be accomplished by engineers skilled in the art.
The foregoing describes one embodiment of the present invention. Modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the invention.
APPENDIX A______________________________________Monolithic LIFT head type A4-4-600This is a four color print head for A4 size printing. The printhead is fixed, and is the full width of the A4 paper. Resolutionis 600 dpi bi-level for medium quality Output. Derivation______________________________________Basic specificationsResolution 600 dpi SpecificationPrint head length 215 mm Width of print area, plus 5 mmPrint head width 5 mm Derived from physical and layout constraints of headInk colors 4 CMYKPage size A4 SpecificationPrint area width 210 mm Pixels per line/ResolutionPrint area length 297 mm Total length of active printingPage printing time 1.3 seconds Derived from fluid dynamics, number of nozzles, etc.Pages per minute 45 ppm Per head, for full page sizeRecording medium 22.0 cm/sec 1/(resolution * actuationspeed period times phases)Basic IC process 1.5 μm CMOS RecommendationBitmap memory 16.6 MBytes Memory required whenrequirement compression is not usedPixel spacing 42.33 μm Reciprocal of resolutionPixels per line 4,960 Active nozzles/Number of colorsLines per page 7,015 Scan distance * resolutionPixels per page 34,794,400 Pixels per line * lines per pageDrops per page 139,177,600 Pixels per page * simultaneous ink colorsAverage data rate 12.3 MByte/sec Pixels per second * ink colors/ 8 MBitsYield and costNumber of chips 1 Recommendationper headWafer size 300 mm (12") Recommendation for full volume productionChips per wafer 36 From chip size and recommended wafer sitePrint head chip area 10.7 cm2 Chip width * lengthSort yield without 0.87% Using Murphy's method, defectfault tolerance density = 1 per cm2Sort yield with 90% See fault tolerant yieldfault tolerance calculations (D = 1/cm2, CF = 2)Total yield with 72% Based on mature process yieldfault tolerance of 80%Functional print 260,208 Assuming 10,000 wafer starts perheads per month monthPrint head assembly $10 EstimatecostFactory overhead $13 Based on $120 m. cost forper print head refurbished 1.5 μm Fab line amortised over 5 years, plus $16 m. P.A. operating costWafer cost per $23 Based on materials cost of $600print head per waferApprox. total print $46 Sum of print head assembly,head cost overhead, and wafer costNozzle and activa-tion specificationsNozzle radius 14 μm SpecificationNumber of actuation 8 SpecificationphasesNozzles per phase 2,480 From page width, resolution and colorsActive nozzles per 19,840 Actuation phases * nozzles perhead phaseRedundant nozzles 19,840 Same as active nozzlesper head for 100% redundancyTotal nozzles per 39,680 Active plus redundant nozzlesheadDrop rate per nozzle 5,208 Hz 1/(heater active period * number of phases)Heater radius 14.5 μm From nozzle geometry and radiusHeater thin film 2.3 μΩm For heater formed from TαAlresistivityHeater resistance 2,095 Ω From heater dimensions and resistivityAverage heater 5.6 mA From heater power and resistancepulse currentHeater active period 24 μs From finite element simulationsSettling time 168 μs Active period * (actuationbetween pulses phases-1)Clock pulses per 2,834 Assuming multiple clocks andline no transfer registerClock frequency 14.8 MHz From clock pulses per line, and lines per secondDrive transistor 42 Ω From recommended deviceon resistance geometryAverage head drive 12.0 V Heater current * (heater + drivevoltage transistor resistance)Drop selection 75° C. m.p. of surfactant sol ortemperature PIT of microemulsionHeater peak 120° C. From finite element simulationstemperatureInk specificationsBasic ink carrier Water SpecificationSurfactant Arachidic acid Suggested method of achieving temperature thresholdInk drop volume 18 pl From finite element simulationsInk density 1.030 g/cm3 Black ink density at 60° C.Ink drop mass 18.5 ng Ink drop volume * ink densityInk specific heat 4.2 J/Kg/° C. Ink carrier characteristiccapacityMax. energy for self 2,715 nJ/drop Ink drop heat capacity * tempera-cooling ture increaseEjection energy per 1,587 nJ Energy applied to heater indrop finite element simulationsEnergy to print 221 J Drop ejection energy * dropsfull black page per pageTotal ink per 0.63 ml Drops per page per color * dropcolor per page volumeMaximum ink flow 0.47 ml/sec Ink per color per page/pagerate per color print timeFull black ink 40.2 ml/m2 Ink drop volume * colors * dropscoverage per square meterEjection ink 38.5 mN/m Surface tension requiredsurface tension for ejectionInk pressure 5.5 kPa 2 * Ejection ink surface tension/ nozzle radiusInk column height 545 mm Ink column height to achieve ink pressure______________________________________
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|International Classification||B41J2/14, B41J2/04, B41J2/005|
|Cooperative Classification||B41J2/04, B41J2/14451, B41J2/005|
|European Classification||B41J2/005, B41J2/14T, B41J2/04|
|Dec 4, 1996||AS||Assignment|
Owner name: EASTMAN KODAK COMPANY, NEW YORK
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:SILVERBROOK, KIA;REEL/FRAME:008387/0716
Effective date: 19960925
|Sep 24, 2002||FPAY||Fee payment|
Year of fee payment: 4
|Nov 16, 2006||FPAY||Fee payment|
Year of fee payment: 8
|Jan 24, 2011||REMI||Maintenance fee reminder mailed|
|Jun 22, 2011||LAPS||Lapse for failure to pay maintenance fees|
|Aug 9, 2011||FP||Expired due to failure to pay maintenance fee|
Effective date: 20110622